Arrangement for making textured film solid cleanser holders

Abstract

Arrangement ( 1 ) for making textured film solid cleanser holders ( 160 ). A solid cleanser feed conveyor ( 2 ) is horizontally rotatably mounted on a first frame work ( 3 ) and provided with a plurality of spaced solid cleanser holding pockets. A film feeding unit comprising one pair of film unwind top roll ( 5 ) and a film unwind bottom roll ( 6 ) are rotatably mounted on a stand ( 7 ) at the feed end ( 8 ) of the feed conveyor. A solid cleanser holder forming unit ( 31 ) is mounted on a second framework ( 35 ) located close to the discharge end of the feed conveyor ( 36 ). A solid cleanser holder sealing unit ( 41 ), a solid cleanser holder cutting unit ( 59 ), a film scoring unit ( 84 ) and a horizontally rotatable waste film carrying conveyor ( 98 ) are mounted on the second frame work in tandem with the solid cleanser holder forming unit. A plurality of film tensioning rollers ( 100 ) and a plurality of film tensioning rollers ( 100 ) and a plurality of film pulling units ( 100 a, 100 nb, 100 c , & 100 d ) are provided in the path of the textured film. An intermittent differential drive unit is connected to the feed conveyor, contra-rotatable conveyors, film scoring unit, waste film carrying conveyor and film pulling units (FIG. 1 ).

We claim:  
     
         1 . Arrangement for making textured film solid cleanser holders comprising a solid cleanser feed conveyor horizontally rotatably mounted on a first frame work and provided with a plurality of spaced solid cleanser holding pockets along the length thereof, a film feeding unit comprising a film unwind top roll and a film unwind bottom roll rotatably mounted on a stand at the feed end of the feed conveyor, a solid cleanser holder forming unit comprising a pair of horizontally contrarotatable conveyors disposed spaced one below the other and mounted on a second framework which is located close to the discharge end of the feed conveyor, a solid cleanser holder sealing unit, a solid cleanser holder cutting unit, a film scoring unit and a horizontally rotatable waste film carrying conveyor mounted on the second frame work in tandem with the solid cleanser holder forming unit and a plurality of film tensioning rollers and a plurality of film pulling units provided in the path of the textured film and an intermittent differential drive unit connected to the feed conveyor, contra-rotatable conveyors film scoring unit, waste film carrying conveyor and film pulling units.  
     
     
         2 . Arrangement as claimed in  claim 1 , wherein each of the solid cleanser holding pockets comprises a pair of spaced upright members fitted across the length of the feed conveyor and the first framework is provided with a flat protrusion at the discharge end of the feed conveyor extending to the feed end of the contrarotatable conveyors.  
     
     
         3 . Arrangement as claimed in  claim 1 , wherein each of the film lamination units comprises a first pneumatic cylinder mounted on the top horizontal member of a first supporting structure and having a first piston reciprocating therein, the first piston rod protruding down from the first cylinder through the top horizontal member of the first supporting structure, the cylinder side and piston side of the first cylinder being connected to a pneumatic supply through a 5-port 2 position solenoid operated direction control valve, a movable laminator plate fitted to a first guide plate which in turn is fitted to the protruding end of the first piston rod up and down slidably engaged over guide rods of the first supporting structure, a stationary die plate fitted at the base of the first supporting structure aligned with the movable die plate, the movable die plate and stationary die plate having formed with the sockets corresponding to the size of the solid cleanser holders and provided with electric heating elements connected to an AC supply through thermostat and temperature.  
     
     
         4 . Arrangement as claimed in  claim 3 , wherein the electric heating elements comprise electric conductors.  
     
     
         5 . Arrangement as claimed in  claim 1 , wherein the solid cleanser holder cutting unit comprises a second pneumatic cylinder mounted on the top horizontal member of a second supporting structure and having a second piston reciprocating therein, the second piston reciprocating therein, the second piston rod protruding down from the second cylinder through the top horizontal member of the second supporting structure, the cylinder side and piston side of the second cylinder being connected to the pneumatic supply through a 5-port 2-position solenoid operated direction control valve, a movable punch plate fitted to a third guide plate which in turn is fitted to the protruding end of the second piston rod and up and down slidably engaged over guide rod of the second supporting structure, the movable punch plate being provided with a film retainer flange at the front side, the film retainer flange being movably held tension spring stressed, a stationary die plate fitted at the base of the second supporting structure aligned with a movable punch plate, the movable punch plate and corresponding stationary die plate having formed with die cavities larger the die sockets in the movable die plate and corresponding stationary die plate registering with the profiles of the edges or frills of the solid cleanser, the bottom of the die cavity in the stationary die plate being open and the base of the third supporting structure being provided with a corresponding opening therethrough.  
     
     
         6 . Arrangement as claimed in  claim 5 , wherein the punch plate is provided with a pair of holes defining neck portions, a pair of screw members each being movably disposed in each of the holes with the heads of the screw members adapted to abut against then shoulders of the neck portions, the film retainer flange being in thread engagement with the edges of the screw members and tension spring stressed against the movable punch plate.  
     
     
         7 . Arrangement as claimed in  claim 1 , wherein the film scoring unit comprises an anvil roller whose shaft is rotatably supported in a pair of first vertical oblong slots provided in a pair of spaced first vertical side plates of a third supporting structure, a rotary disc cutter disposed across and close to the anvil roller and fitted on a shaft rotatably height adjustably mounted in the first vertical oblong slots in the first vertical side plates and stressed by tension springs in abutment with the edges of first setting screws secured through the top horizontal member of the fourth supporting structure in thread engagement therewith and provided with first lock nuts.  
     
     
         8 . Arrangement as claimed in  claim 1 , wherein each of the film pulling units comprises a pair of horizontally contrarotatable rollers disposed one below the other in contact and having their shafts rotatably mounted in a second pair of second vertical oblong slots provided in a pair of spaced second vertical side plates of a fifth supporting structure, the top roller being height adjustable with second setting screws secured through the top horizontal member of the fourth supporting structure in thread engagement therewith, the edges of the second setting screws being provided with second lock nuts.  
     
     
         9 . Arrangement as claimed in  claim 1  wherein the intermittent differential drive unit comprises a geared motor connected to the feed conveyor, contrarotatable conveyors, film scoring unit, waste film carrying conveyor and film pulling units through sprockets and chains and gears and a 6-station. Geneva drive, in which the teeth ratio of the sprocket on the geared motor shaft to the sprocket on the Geneva driver shaft in 2:3 and the teeth ratio of the sprocket on the geared motor shaft to each of the sprockets of the feed conveyor, contrarotatable conveyors, film scoring unit, waste film carrying conveyor and each of the film pulling units is 1:1 and the teeth ratio of the gears of the shafts of the film scoring unit and each pulling unit is 1:1.  
     
     
         10 . Arrangement for making textured film solid cleanser holders substantially as herein described particularly with reference to FIGS.  1  to  18  of the accompanying drawings.